Container and lid assembly

ABSTRACT

A plastic container and lid assembly for storing liquid coating materials including a container and a lid. The container has a body with a bottom wall, at least four sidewalls and a neck. The neck defines a wide mouth opening and including threads for receiving mating threads on the lid. The lid also has a plurality of lugs, preferably two lugs, extending radially from the lid and terminating at or before the lugs extend beyond the container sidewalls when the lid is in sealed engagement with the container. The body also has an integral handle for lifting the container and the container neck supports a bail-type handle also for lifting said container. The integral handle and bail-type handles do not extend beyond the container sidewall. The container and lid assembly having an effective packing footprint and an effective packing volume which substantially conforms to the effective packing footprint and the effective packing volume of a conventional metal paint can.

PRIORITY CLAIM

This Application is a Divisional of co-pending U.S. application Ser. No.10/126,481, filed Apr. 18, 2002, which claims the benefit of U.S.Provisional Application No. 60/284,476, filed Apr. 18, 2001 and U.S.Provisional Application No. 60/292,364 filed May 21, 2001. The entiretyof U.S. application Ser. No. 10/126,481, U.S. Provisional ApplicationNo. 60/284,476, and U.S. Provisional Application No. 60/292,364 arehereby incorporated by reference.

FIELD OF THE INVENTION

The application relates generally to containers and more specifically toa plastic container used to hold paint and similar coating materials.

BACKGROUND OF THE INVENTION

The most common way to store paints or other coatings has been withincircular metal cans utilizing removable metal lids. In use, the lid isremoved using a prying tool, the paint is stirred and then poured fromthe can. Alternatively, a brush is dipped directly into the can and thepaint upon the brush is applied to an object. Most metal cans, such assteel paint cans, are moved and carried using a bail made from a steelwire and mounted in bosses on opposite sides of the container.

Traditional metal paint cans have numerous drawbacks which are obviousto anyone who has ever undertaken a painting project. First, removal ofthe lid can be difficult because a prying tool is required. A lidremoval tool is fairly efficient, but often a screwdriver is usedinstead making the task more difficult. Replacement of the lid is alsodifficult in that a hammer or mallet is required to completely reseatopposed mating grooves on the lid and container. Alternatively,individuals often step on the top of the can to press the lid intoplace. This practice may be hazardous if one loses their balance, andmessy when paint remains in the container grooves as a result of thepouring process.

Over time, due to the moisture inherent within the paint, metal pailsand lids have a tendency to rust or corrode. If rust pieces fall intothe paint, they often render the paint useless. Metal paint cans arealso susceptible to impact damage when they are dropped, or impactedfrom the side. Once the can is deformed, seating and reseating the lidcan be difficult and it can be difficult to return the can to a desiredshape.

Pouring paint from metal paint cans is yet another difficult task due tothe can's configuration. Flowing paint is difficult to guide because nospout formation exists upon the can. Paint usually runs down the side ofthe can and fills the container grooves in the lid seat area. The resultis a messy container which is difficult to open upon next use.Manufacture of paint cans has also been difficult. The formation andattachment of metal wire bail handles is a difficult task to perform.

What is desired is a new paint and coating storage container which hasimproved properties of convenience, durability and pourability. Such acontainer would have an easily removable and replaceable lid. Thecontainer would also be simple to handle. The new container would alsobe comparable in capacity and dimensions with conventional metal storagecontainers so shipping, storage and in-store mixing can be performedusing existing methods and systems already in place.

SUMMARY OF THE INVENTION

The present application provides an improved plastic container and lidassembly for storing liquid coating materials. The assembly includes acontainer and a lid. The container has a body with a bottom wall, asidewall and a neck. The sidewall may be a circular cross sectionalconfiguration, or a rectangular configuration, in which case, at leastfour sidewalls are provided. Where four sidewalls are provided, thedistance between one sidewall and an opposite sidewall is equal to thediameter of a conventional one gallon metal paint can or a conventionalone quart metal paint can, depending on the size of the assembly.Moreover, the effective volume of the assembly is identical to that of aconventional paint can, such that the assembly of the presentapplication may readily replace conventional paint cans.

The neck defines a wide mouth opening which includes threads forreceiving mating threads on the lid. The threads are preferably a doublehelix to provide for specific alignment of the lid with respect to thecontainer body. The double helix thread on the lid engages the neckthreads such that sealing engagement of the double helix thread isprovided on the neck threads after between one half and three quartersof one revolution.

The lid has two or four lugs extending radially from opposite sides ofsaid lid. The lugs terminate at or before the lugs extend beyond thecontainer sidewall(s) when the lid is in sealed engagement with thecontainer. The body may also include an integral handle for lifting thecontainer. A second handle may also be provided. The second handle maybe a bail-type handle supported on the container neck also for liftingthe container. The integral handle and bail-type handle do not extendbeyond said container sidewall. Thus, the container and lid assemblyhave a footprint which substantially conforms to the footprint of aconventional metal paint can. In the preferred embodiment where the foursidewalls are joined and define four corners, the lugs are aligned overthe corners when the lid is in sealed engagement with the container.

The integral handle included in the container body may be hollow, and isformed at one of the four corners of the container. When the lid is insealed engagement on the container, one of the lugs is aligned over theintegral handle. The integral handle forms a hollow vertical pillarwithin the body at the one corner of the body, with the pillar defininga cavity extending from one sidewall to an adjacent sidewall. Thealignment of the lugs of the lid and bail-type handle over the cornersof the container, within the boundaries of the sidewalls of thecontainer during sealing engagement of the lid on the container, alsofacilitates the replacement of conventional metal paint cans by thepresent assembly. When all elements of the assembly are aligned withinthe boundary of the sidewalls, the effective packing footprint of theassembly is substantially equal to that of a conventional paint can.

A method of mixing paint within the rectangular configuration of theplastic paint container and lid assembly of the present application isalso provided. In the method, a weighted square sleeve within aconventional paint mixing apparatus is provided for securing theassembly during operation of the mixing apparatus to mix coatingmaterial within the assembly. The integral handle is aligned within theweighted corner of said sleeve during mixing. An alternative method formixing is also provided wherein weighted plugs are provided within thecavity formed by the integral handle. The assembly of the presentapplication reduces the time required for mixing by one half of the timerequired for mixing conventional paint cans.

Additionally, a method of storing the assembly is also provided whereinfour containers are placed upon a pallet or within a box with theintegral handle of each container oriented towards the exterior of thepallet or box.

These and other features and advantages will become apparent from thefollowing figures and detailed description.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 a shows an exploded view of a container of the presentapplication;

FIG. 1 b shows a “no-tool” method of lid removal from a container;

FIG. 1 c shows a second “no-tool” method of lid removal from acontainer;

FIG. 2 a shows a bottom view of a container;

FIG. 2 b shows a side view of a container;

FIG. 3 shows an alternate side view of a container;

FIG. 4 a shows a perspective view of one embodiment of a containerinsert;

FIG. 4 b shows a side view of the container insert;

FIG. 4 c shows a top view of the container insert;

FIG. 4 d shows a cutaway view of the container insert;

FIG. 4 e shows a top view of an alternate insert embodiment;

FIG. 5 shows an alternative embodiment of a container insert;

FIG. 6 shows a perspective view of a container with an embodiment with atwo-piece bail-type handle;

FIG. 7 a shows a perspective view of an embodiment of a one-piecebail-type handle detached from a container;

FIG. 7 b shows a perspective view of the embodiment of a two-piecebail-type handle detached from a container;

FIG. 8 a shows a side view of a container lid;

FIG. 8 b shows a bottom view of a container lid;

FIG. 8 c shows a cutaway view of a container lid;

FIG. 9 a shows a side view of a container with handle plugs used duringmixing of paint within the container in a shaker apparatus;

FIG. 9 b shows a side view of a container with handle plugs in positionand ready for placement into shaker apparatus;

FIG. 9 c shows handle plugs apart from a container;

FIG. 10 shows the footprint of the container of the present application,as compared to a conventional paint can;

FIG. 11 shows an alternate embodiment of an integral handle of acontainer of the present application;

FIG. 12 shows a top view of an open container of the presentapplication;

FIG. 13 shows a cutaway view of an insert and lid secured in place on acontainer;

FIG. 14 shows a method of arranging multiple containers;

FIG. 15 shows a preferred orientation of an insert with respect to therest of a container;

FIG. 16 a shows a container with a vented lid;

FIG. 16 b and 16 c show accessories used with the container of thepresent application;

FIG. 17 shows a schematic diagram of a manufacturing system formanufacturing, filling and additionally preparing the container of thepresent application for shipment or storage;

FIG. 18 shows a container with a fluid level indicator;

FIG. 19 shows a container with an alternate lid embodiment;

FIG. 20 shows a container with internal ribs;

FIG. 21 shows a retrofit sleeve insert for a shaker machine;

FIG. 22 a shows the theoretical path of moving fluid in the containerintegral handle as the fluid within the container is mixed;

FIG. 22 b shows the theoretical path of moving fluid within thecontainer during mixing;

FIG. 23 shows the insert in position within the neck of the container;

FIG. 24 shows two containers in stacked configuration; and

FIGS. 25 a to 25 d show various alternate container and lidconfiguration embodiments.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1 a, a schematic view of the components of thecontainer 50 and lid 100 assembly is shown. The assembly comprises acontainer 50 having a handle 84, a bail 120, an insert 150, and a lid100 having lugs 108.

Container (and Materials)

Referring to FIGS. 2 a, 2 b and 3, the container 50 comprises a body 51,bottom wall 52, sidewall(s) 54, a neck 66, and one or more handles 84.In the illustrated embodiment the bottom wall 52 is square, but in otherembodiments may be rectangular or circular. The body 51 is one piece andis preferably made from any polymer material which can be blow molded,for example, high density polyethylene (HDPE) or polyproylene. Use ofthese materials, as well as the design of the container 50, result inthe container suffering a lesser amount of damage when dropped from aheight of about 48 inches or about 120 cm, as compared to a conventionalpaint can dropped from an equivalent height. The reduction in damagereduces the number of containers returned to the manufacturer due toshipping or other damage making the product undesirable to consumers.The bottom wall 52 functions as the base of the container 50, providingstability when placed upon a flat surface. The bottom wall 52 mayinclude an indentation 56. As illustrated in FIG. 24, the indentation 56has a shape similar to the shape of the lid 100 so that the lid 100 ofone container 50 mates with the bottom wall 52 of a second container 50when multiple containers are stacked.

The bottom wall 52 of the body 51 is integrally formed with thesidewalls 54 of the container 50. Referring to FIG. 1 a, the body 51illustrated includes four sidewalls 54. The sidewalls 54 may be whollyor partially formed from a transparent material, such as polyethyleneterephthalate (PET). The transparent material permits the liquid withinthe container to be observed. FIG. 18 shows a container 50 including anarrow band 58 of transparent material in the handle 84 to allow fluidlevel to be observed. The container 50 may additionally includegraduations which allow the level of liquid remaining within thecontainer 50 to be quantified.

The number and shape of the sidewalls 54 depend upon the overall shapeof the container 50. A round container 50, as shown in FIG. 1 b includesa single sidewall 54 while a rectangular container 50 shown in FIG. 1 aincludes four sidewalls 54. The sidewalls 54 illustrated in FIG. 1 ahave a flat smooth surface. Alternatively, the sidewalls 54 may beslightly contoured and somewhat roughened or textured, as illustrated inFIG. 2 b, to facilitate the application of labels and the like andsimplify a method of blow molding the sidewalls 54. In a rectangularshaped embodiment with more than one sidewall 54, each sidewall 54 meetsan adjacent sidewall 54 at a corner 78. The rectangular shapedembodiment provides increased visibility for labels attached tosidewalls 54 as compared to a conventional cylindrical paint can.

Such increased visibility provides sales and marketing advantages, asthe consumer is more readily able to read and review the materialprovided on a flat container label.

The corners 78 in the illustrated embodiment are preferably rounded forincreased strength, which may be required when the filled containers 50are compressed during stacking. Additionally, while the corners arerounded, the amount of rounding cannot be so great as to decrease therequired volume of the container. Where the container 50 is forreplacement of a conventional paint can which holds one (1) gallon ofpaint, the container requires a volume of at least 139 ounces, whichprovides for some head space between the fluid level and lid 100. In thepreferred embodiment, each corner 78 may be rounded to a radius ofapproximately 0.75 inches (19 mm).

Additionally, the sidewalls 54 illustrated in FIGS. 2 b and 3 are alsorecessed, such that the top and bottom portions 86 and 88 of thecontainer 50 which include rounded corners form horizontallystrengthening ribs 90. The ribs 90 horizontally surround the top andbottom portions 86 and 88. Additionally, a vertical rib 92 may beprovided between the top and bottom portions 86 and 88. FIG. 2 b showsan exteriorly projecting rib along the corner opposite an integralhandle 84. FIG. 20 shows numerous interiorly projecting ribs 94 on acontainer 50. Interiorly projecting ribs 94 add strength to thecontainer 50 and aid in the fluid mixing process by breaking up fluidstreams along the sidewalls 54 of the container 50. The corner 96opposite the integral handle 84 in the FIG. 3 container embodiment maybe contoured with a lower profile to avoid becoming a barrier orinterference to liquid as it is being poured from the container 50. Inthe rectangular embodiments of the present application, each sidewall 54also has an imaginary middle line “M” which extends from the top of thesidewall 54 to the bottom of the sidewall 54. The middle line “M” ispositioned equidistant from each corner 78 of the sidewall 54. When thelid 100 of the container 50 is screwed into a sealed position, the lugs108 of the lid 100 may be aligned with the corners 78 between thesidewalls 54 or the middle lines “M” of a sidewall 54, depending on theembodiment.

Container Interchangability with Conventional Paint Cans

Referring to FIG. 10, the container of present application is preferablysized to easily replace conventional cylindrical metal paint cans due toits substantially equal effective packing volume. The effective packingvolume includes the effective packing “footprint” (a function of widthand depth) of the container, as well as the effective packing height ofthe container, and is comparable to the footprint and height of aconventional metal paint can. The effective packing volume is a productof effective packing footprint times the effective packing height. Theeffective packing volume is important for aspects of manufacture,manipulation, storage, and use of the present container as a substitutefor a conventional metal paint can. With a substantially equal packingvolume, the present container may often be handled in conventionalmachinery, as well as packed, filled, labeled, shipped, displayed,handled, and used in ways which are conventional and currently in use bymanufacturers, retailers and consumers. Embodiments of the container 50“match” the effective packing volumes of conventional paint cans whichhold one gallon or one quart, as well as metric sized cans which arestandard in Europe and other parts of the world. The dimensions of aconventional one gallon cylindrical paint can, having a circular crosssection, are approximately a height of 7.68 inches and a diameter ofapproximately 6.63 inches. The circular cross section of theconventional can may be inscribed within the cross section of therectangular container 50 embodiment of the present application,resulting in substantially equal effective packing footprints. The depthand width of the rectangular container embodiment are substantiallyequal to the diameter of the conventional cylindrical can, providing aone quarter inch margin for manufacturing tolerances. The effectivepacking height, which is equal to the height of the container and lidassembly combination, of the rectangular container embodiment willlikewise be substantially equal and within one quarter inch of theeffective packing height of the conventional can and lid. Thus, forexample, despite the very different geometry of the container 50 and itsintegral handle 84, the container holds an amount of material which isidentical to the amount conventional cylindrical metal can may hold—onegallon—while leaving sufficient “head space” between the lid 100 and thefluid material within container 50 in each. The effective packing volumeis also substantially equal. With a substantially equal packing volumeas compared to a conventional can, the container 50 of this applicationmay readily replace conventional cans.

Integral Handle

The illustrated container 50 of FIGS. 1 a-c, 2 a-b and 6 includes anintegral handle 84. The integral handle 84 may be a vertical pillarwithin the container and formed on one corner 78 of the container 50.The integral handle 84 may be hollow or solid, but is preferably hollowto facilitate mixing of the liquid within the container 50. Like thecontainer 50, the handle 84 may be wholly or partially transparent. Thehandle 84 is sized to allow comfortable gripping by a variety ofconsumers. The handle 84 greatly adds to the overall strength of thecontainer 50, particularly with respect to vertical loads. The handle 84is rounded in cross-section for comfortable handling. Referring to FIG.6, the handle 84 includes an interior face 80 which defines part of acavity extending from one sidewall 54 to an adjacent sidewall 54. Thecavity is also formed by an interior wall 82 extending from one sidewall54 to an adjacent sidewall 54. The illustrated interior wall 82 isplaner.

As shown in FIG. 12, the neck of the container defines a wide mouthopening which has a diameter which is so large that the interior wall 82extends into the diameter of the wide mouth opening. The integral handle84 may be used in conjunction with or as a replacement for a secondhandle of a bail-type handle 120 described in more detail below.

Container Neck

The sidewalls 54 of the container 50 merge into an integral neck 66 asshown in FIG. 3. The neck 66 includes a vertical portion 70 which has awide mouth opening. The neck 66 has a diameter which is less than thatof the container 50 at its sidewalls 54. The sidewalls 54, at the topportion 86 which is intermediate the sidewalls 54 and the neck 66, maybe rounded for strength and to produce a smooth junction between thesidewalls 54 and the neck 66. Similarly, the corners 74 at the junctionof the sidewalls 54 in the top portion 86 are also rounded. Althoughrounded, the corners may be sharply angled to maximize the volumecapacity of the container. One or more of the corners 74 may also berecessed relative to the other sidewall dimensions, as previouslydiscussed, to allow for appropriate clearance for a paint stream as itis poured from the container 50 or a spout 160. As the diameter of theneck 66 is somewhat smaller then the width of the container 50, ahorizontal portion 68 is provided between the neck 66 and the sidewalls54, spanning the distance between a vertical portion 70 of the neck 66and the top of the sidewalls 54. The length of this horizontal portion68 varies, depending upon the difference between the width betweenopposite sidewalls 54 of the container 50 and the diameter of the neck66 at its vertical portion 70.

The vertical portion of the neck may include a physical or imaginary“fill line” for liquid placed within the container 50. In a rectangularembodiment of the container 50, the fill line for 128 ounces of fluid islocated less than one inch from the top of the neck, and preferablyapproximately 0.77 inches from the top of the neck 66. The fill line for131 ounces of fluid, the theoretical maximum coating material andpigment amounts required to create any shade of tinted material, ispreferably approximately 0.56 inches from the top of the neck 66. Thevertical portion 70 of the neck 66 also preferably includes a bail seat72. The bail seat is a portion of consistent vertical diameter on theneck 66 and onto which a bail type handle 120 may be attached. As shownin FIG. 13, the bail seat may be bordered on its top side by a lip 73.The lip 73 has a diameter which exceeds that of the bail seat 72, thus,allowing the bail handle 120 to snap over the lip 73 into a lockedposition on the bail seat 72. The bail 120 may be snapped into positionby manual application of force or by the action of the lid 100 beingscrewed onto the container 50. A bail handle 120 may rotate freely aboutits seat 72, as in the embodiment of FIGS. 1 a and 1 b, or may be keyedto the seat for specific alignment on the container body 51, as in FIG.6. In the fixed bail handle embodiment shown in FIGS. 3, 6 and 7 b, atab 122 extending from the bail 120 fits within an indentation 75 on theseat 72 in the neck 66 or vise-versa. Referring back to FIG. 3, the neck66 includes a threaded surface 76 above the lip 73. The threaded surface76 may include a single continuous thread to secure and seal the lid 100into a closed position upon the container 50. In the preferredembodiment, the threaded surface 76 comprises a double helix thread. Thedouble helix thread ensures that the lid 100 begins to engage the neck66 at a predetermined position, such that when the lid 100 completes itsrotations on the neck threads 76 and is tightly sealed, the lugs 108upon the lid 100 are positioned at a predetermined location. In thepreferred embodiment of a lid 100 with two lugs 108, the predeterminedlocation of the two lugs 108 in sealed position is with one aligned overthe integral handle 84 and another over a corner opposite the integralhandle, as illustrated in FIG. 6.

Referring to FIG. 12, the interior of the neck 66 of the container 50may include numerous insert seats 98. The insert seats may beprojections extending from the interior surface of the neck 66. Theinsert seats 98 provide a place for an insert 150 to rest. The neck 66may also include one or more tabs 99 extending from its inner surface.One tab 99 is designated to mate with a mating notch 154 formed in theinsert 150 to help position the insert 150 into a desired orientation asshown in FIG. 23. An embodiment of the neck 66 with more than one tab 99will only have a single tab 99 which is sized to mate with the notch 154upon the insert.

Container Inserts

FIGS. 4 a-4 e show one type of insert 150 which may be placed within theneck 66 of the container 50. The insert 150 may be manufactured byinjection molding from polypropylene. The insert 150 includes an outerwall 152 around the outside which when the insert is in place abuts theinner surface of the neck 66. The outer wall 152 may define a notch 154in one position along its bottom. This notch 154 mates with the tab 99of the neck 66, as described above, to align the insert 150 in a desiredposition as shown in FIG. 23.

Referring back to FIGS. 4 a-e, in one embodiment of the application, theinsert 150 also includes a spout 160. The spout 160 may be formed aspart of a web 156 extending across a portion of the insert interior. Theweb 156, and the radial extension of the spout 160, does not exceed thediameter of the outer wall 152. The height of the spout 160 may,however, extend above the top of the insert outer wall 152. For example,the spout portion extends radially upward from the wide mouth opening bya distance less than the radius of said insert. The spout 160 may be aportion 172 of the interior of the web 156, which is flared upwardly. Asthe flared portion 172 extends upwardly, it may become more verticalwhich helps provide a preferred stream profile when liquid within thecontainer 50 is poured. The top of the flared portion 172 of the spout160 is slightly angled from front to rear to lessen the chance ofscraping the spout 160 insert against the underside of the lid 100 whenthe lid is threaded into engagement on the neck 66 of the container 50.

The spout 160 has an arcuate shape in horizontal cross section. FIG. 4 cshows the spout 160 having a preferably “U” shape in horizontal crosssection. In one embodiment of the application, the distance from thespout's cusp 174 to an imaginary line between the two rear edges 176 ofthe spout is approximately 2 to 3 inches or 2.4 inches, and the radiusof curvature of the spout 160 at the cusp 174 is approximately 1 inch orabout 2.5 cm. The spout 160 may have a narrow diameter of about twoinches to restrict undesired large flow rates of paint and to provide asmooth pouring stream. The spout 160 may have rounded rear edges 176 toprovide superior strength and minimize interference with a brush beingdipped into the container 50. Specifically, a large brush, such as a 4inch wide or 10 cm wide brush, should be easily permitted access intothe container 50 through the spout 160 or other insert 150, into thecontainer interior. As shown in FIGS. 4 a-e, extending from its top tobottom on its interior surface 158, the spout 160 may be contoured toprovide a desired shape to assist in the pouring of paint. The spout160, at its cusp 174, has a small thickness of approximately 0.03 inches(0.76 mm) to prevent excessive dripping of a terminated paint stream.Smaller thicknesses become difficult to injection mold. As shown in FIG.4 d, extending from its top to bottom on its exterior surface, the spout160 may be contoured to provide a desired shape for draining paint orother coating material back to the interior of the container 50following the pouring process. The spout 160, in this regard, works inconjunction with a flowback channel 164 within the web.

The flowback channel 164 extends from the base of the spout 160 to theinner wall 151 of the insert 150. The flowback channel 164 maycompletely surround the spout 160 and is outside of, and beneath thespout 160. The flowback channel 164 may have a curved base. Within theweb 156, the flowback channel 164 may be pitched from a higher positionat the front to a lower position at the rear of the web to 156 ensurethat following pouring, the liquid within the flowback channel 164 isreturned to the container interior.

In another embodiment of an insert, as shown in FIG. 5, the insert 150may include a flat upper surface 166 which defines a multi-functionalopening. A forward pouring section of the opening functions as a spout160′. This spout 160′ embodiment does not extend upward from the insertupper surface 166. A transverse section of the opening functions aspassage for entry of a brush. The flat backwall 167 of the transverseportion of the opening can be used to wipe a portion of paint off adipped brush. A rear portion of the opening functions as a stirringstick scraper 162. The rear portion of the opening is very narrow and isoriented transversely from the section allowing passage of the brush.

Bail Handle

Referring to FIG. 6, a handle, also referred to as a bail or bail-typehandle, 120 may be used to lift the container 50. The bail 120 may bemanufactured by an injection molding process, of materials such aspolyethylene. The bail 120 includes an arcuate member 124 which may bedirectly affixed to the neck 66 of the container 50 or affixed to a hoop126. The hoop 126 and arcuate member 124 may be formed from a singlepiece of polymer or multiple pieces. In a single piece embodiment, shownin FIG. 7 a, the arcuate member 124, in a non-lifted state, restsgenerally parallel with the major plane of the hoop 126. The singlepiece embodiment may be manufactured from medium density polyethylene(MDPE). As the bail 120 is lifted, the arcuate member 124 twists nearthe joint with the hoop 126, and becomes generally perpendicular to thehoop 124. The hoop 124, which may be manufactured from high densitypolyethylene in a multi-piece embodiment, circumscribes the neck 66 ofthe container 50 and abuts the bail seat 72 as described above.

In a multiple piece embodiment, shown in FIGS. 6 and 7 b, a socket anddisc joint 128 may join the arcuate member 124 to the hoop 126. Thearcuate member 124 may have a continuous variable cross section and maybe manufactured from low density polyethylene for comfort. The arcuatemember 124, although integrally formed, may include a plurality ofdifferent shaped subsections 130. These subsections 130 may be curvedand/or straight. The arcuate member 124 may include a central subsection132 which may be flat or may be curved. In a preferred embodiment, thecentral subsection 132 is wider and thicker than the remainingsubsections 130. The central subsection 132 may also be rounded on itsunderside to provide comfort during manual lifting of the container 50.When the central subsection 132 is arcuate, the bail handle 120, whenextended such that the container 50 is hung from an object or carried bya user, easily centers itself with respect to the object to providestability to the hanging container 50. The central subsection 132 mayalso be oversized with respect to the rest of the bail handle 120 toprovide comfort during carrying by hand.

The arcuate member 124 of the bail 120 may be free swinging or maytoggle over an edge of the neck 66 of the container or a lug 108 on thecontainer lid 100. This toggle feature prevents undesired swinging ofthe bail 120. Also in a separate embodiment of the application shown inFIG. 6, the arcuate member 124 of the bail 120 may be locked in loweredposition by one or more lugs 108 upon the lid 100 or may be free toswing over and around the lugs 108. The socket and disc 128 of the bail120 may be shaped to provide a preferred resting point along a path ofswing, such as a position where the arcuate member is raised directlyvertical. The arcuate member 124 and hoop 126 may be two separate pieceseasily snapped together at the disc and socket joint.

The bail 120 may preferably be sized to have a maximum width which doesnot exceed the width from sidewall to sidewall within a rectangularembodiment of the container. Similarly the bail 120 may preferably besized to have a maximum width which does not exceed the diameter of thesidewall in a cylindrical embodiment of the container.

Lid

Referring to FIGS. 8 a-c a lid 100 may be shown which is engaged withthe threads 76 on the neck 66 of the container 50. The lid 100 may beformed by an injection molding process, and manufactured from materialssuch as polypropylene. The lid 100 may have a substantially flatsurface, as shown in FIG. 1 b, or a stepped top surface having raisedgripping ribs as shown in FIGS. 8 a-c. In the FIGS. 8 a-c embodiment, alower section 104 and an upper section 106 are provided. The uppersection 106 provides clearance for the spout 160 of the insert. The sideof the upper section 106 mates with the bottom wall 52 of an adjacentcontainer 50 for stability in stacking as previously stated. The uppersection 106 may have a diameter which is less than the lower section104. The lower section includes 104 a plurality of lugs 108 extendingradially outwards from an exterior surface. The lower section 104 mayinclude interior threads 102 which communicate and mate with the doublehelix threads 76 on the neck 66 of the container 50. As previouslystated these threads 102 may be in a double helix to enable precisepositioning upon tight or sealing engagement of the lid 100 on thecontainer neck 66. The preferred embodiment of the lid 100 includes twolugs 108. An alternate embodiment includes four lugs 108 as shown inFIGS. 19 and 25 d. The lugs 108 may be evenly spaced about thecircumference of the lid.

FIG. 1 b illustrates the hand opening of the container using the lugs108 on the lid 100. By providing a container 50 with a lid 100 that canbe opened by hand, no tools are required, which in a conventional metalpaint can are typically required, and also have a tendency to damage thepaint can during opening. Thus, the container 50 and lid 100 assembly ofthe present application provide for “no-tool” opening. In a closedposition, a lug 108 upon the lid of the container may be within thereach of a user's thumb who is grasping the integral handle 84 of thecontainer 50. The lugs 108 also are within the width of the sidewalls ofthe rectangular container when the lid 100 is in a sealed position,although the lugs 10 may exceed the width of the sidewalls duringapplication or removal of the lid 100. By sweeping his or her thumb indifferent directions, the user may apply force to either side of the lug108 and in doing so open or seal closed the container lid 100. Thismethod is equally effective when the integral handle 84 is grasped witheither the user's left or right hand. When additional force is required,both of the user's hands may be laid upon opposite corners of thecontainer 50 as shown in FIG. 1 c. The desired corners are aligned withthe lugs 108 upon the lid 100. Force is applied to the lugs 108 by thethumb upon one of the user's hands and the finger upon the opposite handto remove or seal the lid into place. In a desired embodiment, the lid100 may be moved from a sealed position by rotation of between one halfand three quarter turns or revolutions to a position where removal ispossible.

As shown in FIG. 13, a horizontal seat 110 extending between the base ofthe upper section 106 and the top of the lower section 104 provides aresting place and sealing point for an insertable elastomeric orflexible seal 62 which may be used in the same embodiment of theapplication. The seal may compress against a flat surface upon theinsert 150. The exterior surface of the upper section may include aplurality of ribs 112 as shown in FIG. 8 a. These ribs 112 make grippingthe lid easier. The smaller diameter of the upper section 106 provides agripping space for an individual with a smaller hand. The ribs 112 alsoprovide mold release advantages in manufacturing. The top 114 of the lid100 may include a recess to receive a label.

Mixing Coating Materials

Referring to FIGS. 9 a, 9 b, and 9 c, the container 50 may include tworemovable handle plugs 200 which are placed within the cavity created bythe integral handle 84 to allow the container to be placed within aconventional mechanical paint shaker apparatus. The plugs 200 serve asweights, and are effective to shift the center of gravity to the centerof the container 50, which makes up for the mass of paint missing due tothe cavity created by the integral handle 84. The handle plugs 200 aremanufactured from any dense material, for example aluminum, weightedwood or polymer materials. The handle plugs 200 are shaped with anexterior surface which becomes flush with the exterior surface of thecontainer when the plugs 200 are in place. The plugs 200 are maintainedin place during the mixing process by a rectangular shaped sleeve orframe 210, (shown in FIG. 21) which secures the container 50 and plugs200. Alternatively, a single plug 200 may be used, which is slid withinthe cavity. The plugs 200 function to provide weight balance to thepaint can while it is in the shaker apparatus. The integral handle 84helps create a vortex effect within the container 50 during shakingwhich provides superior mixing. In comparison, a blend of paint in aconventional paint can which takes 2.5 to 3 minutes to mix thoroughly ina shaker apparatus may be mixed in approximately half of that timewithin the container of the present application in the same shakerapparatus.

A conventional paint mixing machine or shaker apparatus which holdscircular cans only, may be retrofitted to hold both the rectangularversion of the container of the present application as well asconventional cans. The square sleeve insert 210 or frame shown in FIG.21 can be easily installed on the conventional machine. Because thedistance from sidewall to sidewall on the rectangular container 50, orthe effective footprint, of the present container is equivalent to thediameter of a conventional can, both types can be placed within theretrofit sleeve 210. Weights 212 attached to the retrofit sleeve 210 maybe used to replace the handle plugs 200 when mixing paint within acontainer 50 of the present application. Appropriately sized weights 212may be attached to the sides of the retrofit sleeve adjacent the cornerabutting the integral handle 84 of the container 50. The weights 212 maybe welded to the sleeve, bolted or clamped in place, or placed within aholding sleeve. The weights 212 are sized to make up for the mass ofpaint missing due to the cavity created by the integral handle 84.

Overall, FIG. 22 shows the improved mixing characteristics, illustratedby the varied stream lines, created by the following components of thecontainer of the present application: integral handle (solid or hollow),flat side walls (in rectangular embodiment), sidewall ribs (incylindrical or rectangular embodiments).

Referring to FIG. 11 another variation of handles 250 used to hold thecontainer 50 of the present application is shown which includes handleindentations 250 on adjacent sidewalls 54 of the container. The handleindentations 250 do not join with each other to form a cavity, whichexists in other handle embodiments previously described. The handleindentations 250 may include ridges or other types of texturing toincrease gripping properties. As shown, the handle indentations 250 mayhave a rectangular shape with height exceeding width.

Referring to FIG. 12, the orientation of the integral handle 84 to thewide mouth opening is shown. At this diameter, the wide mouth opening isat least 80% as large as the distance between opposite side walls of thecontainer, and is preferably at least 83% as large. The interior wall 82defining the cavity portion of the integral handle 84 is verticallyaligned within, and thus extends into, the wide mouth opening.

Insert Lock

Referring to FIG. 13, a detailed cutaway view of a pinching lockmechanism is shown between the neck 66 of the container and the insert150. The insert 150 includes a cantilever section 178 with a hooked end180. The insert 150 also includes a beveled section 182 adjacent to thecantilever section 178. The cantilever section 178, in combination withthe beveled section 182 of the insert 150 functions to lock the insert150 into place over and around the neck of the container. In operation,the insert 150 which is initially detached from the neck 66 may beplaced within the opening defined by the neck 66. A portion of a taperedsurface 184 of the insert 150 makes contact with a portion of the top ofthe neck 66. As the insert 150 is forced downward, the tapered surface184 of the insert 150 slides along a portion of the top of the neck 60until the beveled section 182 of the insert 150 is reached.Simultaneously, the beveled section 182 of the insert 150 finds theinterior beveled section 79 of the neck 66 and the cantilever section178 of the insert 150 with its hooked end 180 closes over the top of theneck 68. The insert 150 is then locked in place until it is forcefullyremoved.

The lid 100 contributes to formation of a seal which prevents spillageor drying out of the paint or other coating material within thecontainer 50. To assist in forming a seal, the lid 100 may include aninner ring and lateral sealing surface. The inner ring 116 extendsdownwardly from the interior side of the lids 100 upper section 106. Thelateral sealing surface may be located above the threaded section of thelid. As the lid 100 is screwed onto the neck 66, the inner ring 116 andlateral sealing surface together squeeze the insert 150. The lateralsealing surface 118 abuts the hooked end 180 of the cantilever section178 and the inner ring 116 abuts the top of the insert 150.

Stacking/Assembly Methods

Referring to FIG. 14, a method for stacking the containers 50 of thepresent application is shown. The method includes placing four or morecontainers 50 upon a support such as a pallet or within a box. Thecontainers are placed such that their integral handles 84 are orientedtowards the exterior of the support. This orientation provides strengthagainst impacts against the side of the group of containers and strengthon the exterior which aides in stacking. A second support and a secondset of at least four containers 50 may then be placed within a box uponthe top of the first set of boxed containers in the same orientation. Inpractice, three additional levels of four boxed containers may be addedto a single pallet. In practice, a second pallet of up to five levels ofcontainers may be placed on top of the first pallet. The containerhandle orientation allows the individual containers to be easily removedfrom a stack formed from multiple pallets and sets.

Referring to FIG. 17, the container of the present application may befabricated and assembled in a compact area of a manufacturing facilityor in side by side manufacturing facilities. In a preferred method, afabrication machine, typically a blow molding machine 300, is located inclose proximity to paint mixing and filling machines 310. A benefit tothis layout is that large container parts do not need to be stored orshipped from facility to facility. In one method of manufacture, amolding facility is located directly next to a paint formulatingfacility and molded container parts are transferred through a passage ina wall from the former to the latter. Final preparation machines such aslabel applicators 320, lid assembly 330 and application machines,assemblers 340 and palletizers 350 may also be located within closeproximity. The application and assembly operations may be performed inany order.

Variations

FIG. 15 shows a container assembled having a preferred alignment of theinsert 150. The spout 160 of the insert 150 is oriented opposite theintegral handle 84. The bail handle 120 is such that when the arcuatemember 124 is lowered, the central subsection 132 may rest directlyabove the integral handle 84. As shown in FIGS. 6 and 25 d, the lugs 108upon the lid 100 are oriented such that a lug 108 is directly above thecontainer corner including the integral handle 84 when the lid is sealedon the container. Thus, all aspects of the illustrated embodiment areproperly aligned for ease of shipping and use of the container and lidassembly by consumers.

Referring to FIGS. 16A, 16B and 16C an embodiment of the application isshown with the container lid 100 including a hole 400 and vent 410combination. The hole 400 may be normally plugged and opened when theliquid within the container 56 is to be used with an accessory orauxiliary device 420, for example, as a paint sprayer. The vent 410 alsomay be normally closed, but opened when the hole 400 is unplugged. Thevent 410 allows air to enter the container 50 to replace liquidwithdrawn, for example, under a vacuum, by an accessory 420 duringpainting or other operations.

Additional advantages and modifications will readily appear to thoseskilled in the art. For example, the container may include additionalreinforcement ribs. Further, other handle cross sectional shapes may beprovided for handling comfort. Also, instructions, numbering and symbolsmay be added to or molded into parts of the container. Therefore, theapplication in its broader aspects, is not limited to the specificdetails, the representative apparatus, and illustrative examples shownand described. Accordingly, departures may be made from such detailswithout departing from the spirit or scope of the applicant's generalconcept.

1. A method of storing plastic containers having integrally formedhandles comprising: a) placing a first set of at least four containersupon a pallet or within a box wherein a handle of each container isoriented towards the exterior of the pallet or box; and b) stacking asecond pallet or box and a second set of at least four containers uponthe top of said first set of containers, wherein a handle of eachcontainer of the second set is oriented towards the exterior of thepallet or box.
 2. A method of storing plastic container assembliescomprising: a) providing a first set of at least four containerassemblies, each container assembly comprising a container and a lid;said container having a body with a bottom wall, at least four sidewallsand a neck; said neck defining a wide mouth opening and includingthreads for receiving mating threads on said lid; said lid comprising aplurality of lugs extending radially from opposite sides of said lid,and terminating at or before said lugs extend beyond said containersidewall when said lid is in sealed engagement with said container; saidbody also having an integral handle for lifting said container; saidcontainer and lid assembly having an effective packing footprint whichsubstantially conforms to the effective packing footprint of aconventional metal paint can; b) placing said first set of at least fourcontainer assemblies upon a pallet or within a box wherein a handle ofeach container is oriented towards the exterior of the pallet or box; c)providing a second set of at least four container assemblies eachcontainer assembly comprising a container and a lid; said containerhaving a body with a bottom wall, at least four sidewalls and a neck;said neck defining a wide mouth opening and including threads forreceiving mating threads on said lid; said lid comprising a plurality oflugs extending radially from opposite sides of said lid, and terminatingat or before said lugs extend beyond said container sidewall when saidlid is in sealed engagement with said container; said body also havingan integral handle for lifting said container; said container and lidassembly having an effective packing footprint which substantiallyconforms to the effective packing footprint of a conventional metalpaint can; and d) stacking said second set of at least four containersupon the top of said first set of containers, wherein a handle of eachcontainer of the second set is oriented towards the exterior of thepallet or box.
 3. The method of claim 2 further comprising: placing saidsecond set of at least four containers on a second pallet or in a secondbox.
 4. A method comprising: blow molding a container comprising a bodywith a bottom wall, at least one sidewall and a neck; said neck defininga wide mouth opening and including threads for receiving mating threadson a lid; said body also having an integral handle for lifting saidcontainer; transferring said container through a passage in a wall to apaint formulating facility; filling said container with paint.
 5. Themethod of claim 4, further comprising: positioning a lid on saidcontainer, said lid comprising a plurality of lugs extending radiallyfrom opposite sides of said lid, and terminating at or before said lugsextend beyond said container sidewall when said lid is in sealedengagement with said container.
 6. The method of claim 5, furthercomprising: applying a label to said container.
 7. The method of claim5, further comprising: placing a set of at least four containers upon apallet, wherein a handle of each container is oriented towards theexterior of the pallet.
 8. The method of claim 7, further comprising:stacking a second pallet and a second set of at least four containersupon the top of said first set of containers, wherein a handle of eachcontainer of the second set is oriented towards the exterior of thepallet.
 9. The method of claim 5, further comprising: placing a firstset of at least four containers within a box, wherein a handle of eachcontainer is oriented towards the exterior of the box.
 10. The method ofclaim 9, further comprising: stacking a second box and a second set ofat least four containers upon the top of said first set of containers,wherein a handle of each container of the second set is oriented towardsthe exterior of the pallet or box.